Going hybrid? maybe?

[JOHNDOE83]

Ive been wanting to do a cr500 or cr250 swap in the EX for a long time now. Just today a guy has a 99 cr250r for sale for $500. The cr250 in that yearish area is said to have around 45 horse power! Also is said to be about 25 lbs lighter then the EX motor.

The dirt bike is whole and in running condition, The pic of the bike looks good, he says the only things needed was plastics and chain rollers, which i dont care about...lol.

I recently have aquired a friend that has a metal shop and will do all the fab work free of charge if I get all the fish out of his pond...lol... which, I have a commercial fishing license and a buyer for all the fish.

So, Im kinda getting paid to have someone do the fab work...lol.

This going in my 400ex drag bike as many of you know.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/dragraces007.jpg


My goal and thinking behind this: " just a theory for now"

Hopefully, I can mount the motor through the swinger bolt as usual and shim it/grind it into place where I need it to be for chain allignment and exhaust fitment. Then I can have my friend make brackets that fit in almost the stock engine mounting locations. "worst case scenario, he makes all new ones"

He has over 30 years of experience in metal fab work and welding, he owns his own buisness, etc... "I have faith in his work"

What do you guys think, I know its harder then it sounds and there will be fitment issues but we have the abillity and equipment to do it fairly quick.

Als theres alot of 250r conversions in the hybrid section with all the useful info I need.

Should I do it, I could be the proud owner of a CR250 400ex hybrid drag quad!!! Tomorrow!!!

Opinions? Facts? what do you think? is that HP rating not even close? let me have it?

[chronicsmoke]

Subscribed, I've been thinking of doing the same thing for a while now. But I want to use a KTM 2 stroke engine (300, 330, or 380).. But the CR conversion already has so much info floating around

[ish416]

I don't see it being that much faster than your current setup. At least not fast enough to justify the price/downtime/time invested vs what you have currently.

As far as 45hp on that bike, I would believe it. Keep in mind however, that they dyno'd those engines in a bike, so that motor makes 45rwhp in a bike and could be 38rwhp in a quad. Heavier tires and axles will create a lot of robbed horsepower. You could lose less power or lose more. I would guess more.

Would it be cool? Yes.
Would it be faster? Maybe.
Should you do it? Only you can decide.

[finsteratv]

I'd do it because even if it does rob some power a CR250 motor has ALOT more potential imo. plus 2 strokes are really fun.

[chronicsmoke]

If you decide to go the CR 250 route, there are guys that work MAGIC on these old 2T. Neil and Carlos (both members on the 250r.net) can make a 55HP stock bore engine. If you throw on a BB cylinder ~350CC you'll be WAY faster than any EX.

[duneslider]

For very inexpensive that engine can make serious power. Look into the engine work Eric gorr does, he is one of if not the top 2t guy. I had him do my YZ work, fast, good, and affordable. I would think you'd be looking at a custom made pipe, unless someone makes a pipe for these conversions. A mismatched pipe won't do any good.

I warn you though, 2t are really easy to work on and very fun to ride.

[chronicsmoke]

Here's some info on the swap from a member that's done it;

http://www.exriders.com/vbb/showthread.php?s=&threadid=395940&perpage=10&pagenumber=1

[mineralgrey01gt]

Thats actually a common swap and they make excellent power. I think those have the factory power valve also. Get in the 250r section and talk to C-LEIGH Racing in there. Thats Neil and he does excellent work. Id do a 265 stroker in it with neil's port work then just hold on cause its a wild ride

[JOHNDOE83]

On my way to orlando to buy a cr250r right now!!!

[chronicsmoke]

Originally posted by JOHNDOE83
On my way to orlando to buy a cr250r right now!!!

I wish there were a 'Like' button for this!

[chronicsmoke]

Originally posted by JOHNDOE83
On my way to orlando to buy a cr250r right now!!!

I wish there were a 'Like' button for this!

[mineralgrey01gt]

Awesome! Wish you were closer id buy that rolling chassis from you

[JOHNDOE83]

Well I bought that 250 last night!!!!

I will have the starting pics of the tear down this weekend!!!

[finsteratv]

what happened to the turbo project?

[honda400ex2003]

subscribed, good luck with it man! should be killer when it is done. if i was going to do a hybrid it would be a 250r motor for sure.

post lots of progress and pics!
steve

[JOHNDOE83]

Happy Thanksgiving everyone!!!

Here are some pics of the cr250r we are using for the conversion.

Can you believe it was only $500. !!!!

http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0048.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0045.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0047.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0046.jpg

[JOHNDOE83]

This bike is said to be stock with aftermarket reeds and the FMF gnarly pipe and some jetting.

Its alot different riding this compared to riding the old 400 motor, the 2 stroke power band and pipe combo are gonna take some getting used to.

The pipe is like a midrange pipe and its kinda hard to keep it on the pipe being that the power is in the middle. But, once your on the pipe this thing gets up and really moves!

Im thinking on selling my EX motor and all the components that go with it so I can afford a shearer custom out of frame pipe.

If I get a good top end pipe and some good porting to match it up and a bigger carb, this will be one fast stock bore/stroke motor!

I think the clutch is slipping a lil to?

[01boneless]

a shame you have to waist a good bike well at least your useing the motor haha looks to be a awsome build subcribed!!

[chronicsmoke]

JohnDoe, You've got me looking at bikes right now, lol.

I'm scoping out this 1993 CR250 with a blown top end for 500$.. I have a Sparks 280 top end that I might be able to put in it..

I wonder if my 426 would fit into a CR250 frame.... That's be awsome! Or, I could rebuild a cheap 125 engine and put it in the bike after too.. Hmmm :uhoh:

[mineralgrey01gt]

Originally posted by chronicsmoke
JohnDoe, You've got me looking at bikes right now, lol.

I'm scoping out this 1993 CR250 with a blown top end for 500$.. I have a Sparks 280 top end that I might be able to put in it..

I wonder if my 426 would fit into a CR250 frame.... That's be awsome! Or, I could rebuild a cheap 125 engine and put it in the bike after too.. Hmmm :uhoh:

Im about 90% sure that the sparks jug will fit but dont hold me to it. I know the bottom ends are extremely close

[JOHNDOE83]

Originally posted by chronicsmoke

I wonder if my 426 would fit into a CR250 frame.... That's be awsome! Or, I could rebuild a cheap 125 engine and put it in the bike after too.. Hmmm :uhoh:

Dude, whats cool about that is I was just thinking of putting my EX motor in the 250 frame and putting a +5in 400ex rear swinger on it creating a long travel trike!!!

They kinda built one just like it in another forum!

http://www.exriders.com/vbb/showthread.php?s=&threadid=437285&perpage=10&highlight=450r trike&pagenumber=2

[JOHNDOE83]

Well I started to take everything apart today.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay051.jpg

I weighed the chassis and it was right at 200lbs without motor or electronics.

I had the motor out so I decided to put it on a scale also, can you guess how much it weighed? it was Motor, all electronics, and battery.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay055.jpg


It weighed exactly 100lbs!!! 105 if you include the oil tank and cooler.

So I was able to accomplish this really fast. So, I decided to go ahead and get the cr250 motor out.

I then weighed it also, It was only 50lbs!!!

Heres the proof!!! scale reads correct also.

EX motor with battery.
http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay057.jpg

CR250R motor!!!
http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay058.jpg


So I also went ahead and did this.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay061.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay062.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay064.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/Workandplay063.jpg

The kick starter has to stick out considerably further, the case swinger mounting location is slightly wider then the EX swinger bolt, the rear swinger bolt whole on the motor has to be shaved to line up the sprokets and a pipe has to be made, unless I can find a out of frame trx250r pipe.

Time to search the web for what others have done.

What do you guys think?

[mineralgrey01gt]

I would use a trx250r pipe not the one that came with it personally. Just dump a little more money into an ESR trx11 pipe. You will love it

[JOHNDOE83]

Im actually worried about the pipe fitment, the cr250 wont fit at all and I dunno if the cr motor sits in the same spot a trx250r motor sits.

I was actually looking at getting that esr trx11 instead of doing a out of frame pipe, but that may be my only option :(

I just dont wanna buy a trx pipe and have it not fit then id have to re sell another pipe, If I knew someone with a 250r I would test fit their pipe first.

Maybe I can find a stock or under $60 pipe to use for a test? Id hate to have to do that though.

A shearer custom might be needed :D

[mineralgrey01gt]

Man too bad your not closer. My brother has my old LRD adjustable pipe hanging in his shed id let you use to see what the fitment would be. Have you tried posting in the hybrid section? Ive seen the swap done a bunch of times and I want to say the pipes fit well but not 100% on that.

[buck440]

for the same price you could of got a cr500 motor. if anything you should of got a trx250r motor so it would fit the quad better or even sell the 400ex and get a trx250r. i think you are going the wrong rout and getting way over your head with not that much to gain to be worth the trouble.

[honda400ex2003]

looks great man!

steve

[BlasterEaten250]

This thread needs to stop it is putting expensive ideas in my head :p

Keep it up!

[audioworks04]

Originally posted by JOHNDOE83
Dude, whats cool about that is I was just thinking of putting my EX motor in the 250 frame and putting a +5in 400ex rear swinger on it creating a long travel trike!!!

They kinda built one just like it in another forum!

http://www.exriders.com/vbb/showthread.php?s=&threadid=437285&perpage=10&highlight=450r trike&pagenumber=2
How does this create long travel by just putting on a longer swing arm?

[JOHNDOE83]

Originally posted by audioworks04
How does this create long travel by just putting on a longer swing arm?

because of the cr250r suspension and front tire.

the pic was to show how it would kinda look like frame wise.

Imagine a cr250 with a quad extended swingarm jacked up to the CRs ride height.

That would be sweet. :D

[JOHNDOE83]

Originally posted by buck440
for the same price you could of got a cr500 motor. if anything you should of got a trx250r motor so it would fit the quad better or even sell the 400ex and get a trx250r. i think you are going the wrong rout and getting way over your head with not that much to gain to be worth the trouble.

Well for 500 i woulda just got a cr500 motor nothing else, for my 500 I got every component needed to make it run other then a pipe.

The cr250 stock has 45hp the trx250r has around the same as a 400ex stock. Thats why in my opinion its better then a trx style motor. It also has 5 gears instead of 6 like trx style, making better gearing for what im using it for.

Also the 400ex frame with a cr motor is only gonna weigh 260lbs. A trx 250r weighs a lil more I think....maybe.

[JOHNDOE83]

Originally posted by BlasterEaten250
This thread needs to stop it is putting expensive ideas in my head :p

Keep it up!

I know right...lol.

[JOHNDOE83]

Originally posted by honda400ex2003
looks great man!

steve

Thanks Steve!!!

Im gonna call the machine shop today and see if I can get that bushing made for the swinger bolt.

Ill post pics again when I have it installed.

[Thumpin440ex]

How are they getting almost double the HP from the cr enigine vs the r engine, giving the same displacement?


John

[mineralgrey01gt]

Originally posted by Thumpin440ex
How are they getting almost double the HP from the cr enigine vs the r engine, giving the same displacement?


John

dirtbikes have a power valve, trx does not. The trx makes more power than a 400ex. ive ridden both in stock form and the 250r walked the hell out of a 400ex so i dont understand that statement but ok. I personally would have went with a 250r to start out with but then again its not my money or went with the cr500 motor. You can run 5 gears in a trx or atc engine. ESR explained to my brother about this but he decided to put 6 in it.

[crownandmonster]

A bone stock TRX r makes right in the neighborhood of 35hp and 27-29hp at the wheels. The CR makes more power due to the powervalve and the higher compression.

[Thumpin440ex]

Originally posted by JOHNDOE83


The cr250 stock has 45hp the trx250r has around the same as a 400ex stock.




John

[JOHNDOE83]

To be honest thumpin, I dont know how true that statement above is.

But the cr has signfigantly more hp then a trx motor, one reason is were talking about a 86ish 250r motor compared to a 98 model motor. Things have been improved over that period of time, also a major mod for HP increase in trx motors is the cr250 ignition, the gearing is different, power valve, ports they actually put cr cylinders on trx motors for more power, the list goes on.

Kinda like a cam'd/ported stock bore EX against a complete stock EX.

Its also the same thing as a service honda srx250r, "so it cant be a bad idea" :D

[finsteratv]

theres a guys near me on CL with an ATC250r motor in a 400ex..service honda. i can getcha a link if you'd like.

[JOHNDOE83]

Originally posted by finsteratv
theres a guys near me on CL with an ATC250r motor in a 400ex..service honda. i can getcha a link if you'd like.

Why would I need that?

A 250r motor regardless of trx or atc is the wrong motor.

[mineralgrey01gt]

Originally posted by JOHNDOE83
Why would I need that?

A 250r motor regardless of trx or atc is the wrong motor.

maybe because the mounts arent that far off of each other but the mounts you really need to worry about is the front, bottom, and top. I wouldnt stress about the back one

[Rohr397]

This is quite a bit off topic but thought I'd mention the idea. The build I'd really like to see done is a Cr125 motor swap. Weight would be an issue but I think for motocross it'd be an awesome play quad. Just throwing that one out there! haha

[JOHNDOE83]

Actually the stock 400ex mounts in the front are almost a perfect match.

The top and bottom have to be made, Im actually going to drop off the swinger bolt and a bushing in about a hour to be cut down to fit the CR swinger bolt hole.

Im using a EX swinger bushing "the long one" and having it cut down to fit the CR motor.

Then if the sprokets line up I can get the mounts made, I think im going to have to grind the case a lil bit at the swinger mount and possibly shim my rear sproket to get everything to line up.

Lets hope its easier then that tho...:rolleyes:

[JOHNDOE83]

Originally posted by Rohr397
This is quite a bit off topic but thought I'd mention the idea. The build I'd really like to see done is a Cr125 motor swap. Weight would be an issue but I think for motocross it'd be an awesome play quad. Just throwing that one out there! haha

I like it :D

125 in a 300ex or blaster frame!

Theres a guy who put a yz85 motor in a blaster somewhere on here.

[mineralgrey01gt]

Thats awesome on the front mounts. Usually thats the biggest pain on those. I know the trx motor mounts are offset on the frame, i figured those may be like that also, but guess not!

[JOHNDOE83]

Well I got the swing arm bolt bushing made and Im ordering a new 400ex swinger bolt bushing kit "I had the long swinger bushing turned down to fit inside the CR motor". So as soon as I get the bushing kit I will line this motor up to the sprokets and begin the next process "making motor mounts".

Ive been thinking of what to do with the pipe situation, If I buy a trx pipe new and have to cut out a inch section to get it to fit, I wont be happy with the end product.

I talked to one company that says they can send me a tack welded pipe that I can move to how I need it then weld it back together, but that kinda sucks.

Another company told me that they will take my build info and have a answer for me in 24 hours, so Know I have to wait for their opinion...wtf...lol.

[finsteratv]

what happened to the turbo build?

[AnotherNewb]

I have one I bought converted if you need pictures of any mounts and such, I would reccomend gusseting the frame at every weld you can, it will shake them loose. Bought mine cheap and pulled it down to frame for sandblasting powdercoating and a frame up rebuild. 91mm piston, shaved head, fully match ported and cpi out of frame drag exhaust. 190 psi compression, should be a beast. Running a 250r +6 swingarm and may not be enough.

[audioworks04]

No company is going to be able to make you a pipe that they can guarantee will fit because they dont know where your motor sits. Your best bet is start with a trx pipe and make it work then send it out to get coated. As I am sure you know, cr motors are not counterbalanced, I would be very worried about your frame. I hope that it is gusseted and all your welds are very good. It will not be as bas as a 500, but it will still be very bad with four wheels.

[JOHNDOE83]

Originally posted by finsteratv
what happened to the turbo build?

I didnt have anyone to help with the project, I tryd calling and talking to megasquirt and other companys that offer parts for turbo'd vehicles.

It was working fine until half throttle then would stall out and die, I couldnt figure out if it was going rich or lean.

Then a race came up and a guy was trying to run me for money, so I took the turbo stuff off and tuned it back for the race, then I havent had the motivation to start it back up.

Now I have a cr400ex project...lol.

[JOHNDOE83]

Originally posted by AnotherNewb
I have one I bought converted if you need pictures of any mounts and such, I would reccomend gusseting the frame at every weld you can, it will shake them loose. Bought mine cheap and pulled it down to frame for sandblasting powdercoating and a frame up rebuild. 91mm piston, shaved head, fully match ported and cpi out of frame drag exhaust. 190 psi compression, should be a beast. Running a 250r +6 swingarm and may not be enough.

Ya dude send me pics, if they are helpful that would be awesome! post them here.

I would like to see the ride anyway with the +6 mines a +7.

[JOHNDOE83]

Originally posted by audioworks04
No company is going to be able to make you a pipe that they can guarantee will fit because they dont know where your motor sits. Your best bet is start with a trx pipe and make it work then send it out to get coated. As I am sure you know, cr motors are not counterbalanced, I would be very worried about your frame. I hope that it is gusseted and all your welds are very good. It will not be as bas as a 500, but it will still be very bad with four wheels.

Ya thats why I want a out of frame 250r pipe, it would kinda fit regardless with some mounting tabs welded somewhere.

The vibration may or may not be bad, Ive seen some threads that say its not bad at all and some that say it rattles their teeth out.

They do sell a heavier flywheel that kind acts as a counter balancer, if its bad ill buy it and try it.

I wonder if a puma kit will fit in a cr motor, even if it needs some modding?

[audioworks04]

Even with an off pipe it needs a mount point somewhere to hold it, you cannot expect the exhaust flange to hold up the full pipe. Why would you want to put a puma on a cr bottom end, it would defeat the whole point of your build, the puma is not a pv motor and the pv on a cr it is part of the cylinder. If you wanted to go puma you would have been much better off to use a trx bottom end with a puma top end. Personally I wouldnt be surprised if your ex that you started with wasnt faster than what you are ending with. Dirt bike conversions are not easy to make "right". Dont get me wrong I understand the want to have something different than others, thats why I built my atc450, best of luck.

[JOHNDOE83]

Originally posted by audioworks04
Even with an off pipe it needs a mount point somewhere to hold it, you cannot expect the exhaust flange to hold up the full pipe. Why would you want to put a puma on a cr bottom end, it would defeat the whole point of your build, the puma is not a pv motor and the pv on a cr it is part of the cylinder. If you wanted to go puma you would have been much better off to use a trx bottom end with a puma top end. Personally I wouldnt be surprised if your ex that you started with wasnt faster than what you are ending with. Dirt bike conversions are not easy to make "right". Dont get me wrong I understand the want to have something different than others, thats why I built my atc450, best of luck.

Ya I understand, the out of frame pipe bolts to the foot peg also. It would have decent support, for piece of mind I was gonna add a additional mount on the frame, maybe in conjunction with the motor mount.

I didnt know the puma wasnt powervalved, Im sure a 310 kit would be all I really need anyway. Besides I cant afford a puma :(

It will deffinetly be faster then the EX was, the HP alone is more then the EX and now the whole quad only weighs 260lbs. It cut 50lbs just switching motors out.

Man there is some sick 450r atv conversions out there, is yours a crf450 or a diff type? Can you send me some pics of your setup? Or even post them here?

My next project is gonna be ATC related.

[audioworks04]

Dont want to take over you post, but you asked for pics so here you go. Hope yours works out good, to say the least hybrids are an adventure.
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0938.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/DSCN0940.jpg
http://i597.photobucket.com/albums/tt59/audioworks04/SEPTCover775-2010.jpg

[JOHNDOE83]

That thing is sweet man!

I wann take the allum cr chassis I have now and do "almost" the same thing!

I wanna use the stock cr front end and rear shock and put a EX +6 rear swingarm on it.

Might use the EX motor, might use a cr125.

[audioworks04]

its not cheap or easy. for the front end youll need triple trees, need forks shortened, need front axle and spacers, need brake adapter, need hub
for the rear, if you use the cr shock you need to use cr linkage and revalve your shock for all the extra weight that is unsprung, and to use the cr link your ex swinger will have to be reworked, you wont want to keep the same height as the cr is stock, or it will be super tippy. As you lower the rear the rake will become longer which is no good. and more importantly you need to add alot to the frame to make it stong enough to handle all that extra weight you added. Lots of little things like pegs, kicker, brake lever, and shifter will become big issues that you dont plan for. Mine is still a work inprogress and will probably never be done.

[JOHNDOE83]

Ok, yesterday I got my swinger bushings and installed the motor through the swinger bolt.

I had to grind both bushings about 1/16th on both to get the motor to fit between and center as the EX motor would.

The sprokets are about 3/16th's from lining up, I have room to shim the front and rear sproket about 1/16th on each and still feel comfortable.

The last 16th I dont know, I can grind one more 1/16th off the left side "short" bushing but after that Id have to grind the motor or swinger a lil bit. "theres just not alota room for error"

As for the pipe, I talked to a few pipe manufacturers, they either need the whole bike or will sell me a built pipe that I can make fit or sell me a partially made pipe. I think Im gonna buy a average out of frame 250r pipe and cut it and extended or bend to make fit.

Im gonna go search the web now to find the best options for the kicker extension.

[rinconrider]

any updates john?

Looks sick!

[JOHNDOE83]

My computer crashed and I haven't been able to get online so I'm typing this on a Android tablet....lol.

I got the swinger bolt taken care of And the sprokets lined up, I also fabbed the front motor mounts.

I got the kicker shaft almost done need to go now and order a second kiker assm.

I found a pipe I'm bidding on and ill have pics and a better description as soon as I get my pc back.

[JOHNDOE83]

I bought a ftz in frame drag pipe on ebay for $175 And thinking back, I almost payed ftz $500 to make me a pipe! Delivery date is said to be on the 19th.

A new/used cr kick start knuckle was also ordered.

Hopefully ill get my cp back this weekend?

[JOHNDOE83]

Got my cp back so heres some teezer pics until I get better ones later today.

this is the template i used to make the front mounts.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/expoject029.jpg


this is the difference between the stock mount and the new template.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/expoject030.jpg


this shows how close the plug is to the gas tank shield, its actually about 1 and 1/4 in away give or take.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/expoject028.jpg


this is how the sprokets lined up.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/expoject027.jpg


The only thing I had to shim once the swinger was bolted up is the front sproket, its a heavy 16th spacer theres still 3/4 of the sproket on the splines.

I might try to grind the swinger a lil bit to get that extra 16th back, but for now the project continues more detailed pics later today.

[05DodgeDakota]

Since you strictly drag race and weight is a big factor, why not do the crf seat conversion

[JOHNDOE83]

Originally posted by 05DodgeDakota
Since you strictly drag race and weight is a big factor, why not do the crf seat conversion

Actually, I am/was gonna do it with the cr seat :D

And build a allum or emt conduit subframe, prob allum.

[05DodgeDakota]

You should come run that thing at dirty foot adventures' sand drags

[JOHNDOE83]

I already have and will again as soon as its done!!

It ran a 5.6 best time at DFA with the ex motor.

[05DodgeDakota]

Ah sorry I missed it. I ride there all the time. I kinda sorta work there

[JOHNDOE83]

heres the update!!

This is how the mounts turned out.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb001.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb002.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb003.jpg

This one isnt bolted in so it looks sloopy but it actuall fits perfect.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb006.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb004.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb005.jpg

This is how the swinger assm looks.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb007.jpg



This is how the kicker knuckle used to look.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb011.jpg

This is it now.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb012.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb013.jpg


It fits in this angle metal for the extension.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb010.jpg

And when i get the new knuckle in it will look like this at the other end for the actual kick start.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb015.jpg

[JOHNDOE83]

my base of operations ... lol.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/exfabb014.jpg

[Stickman400]

That looks pretty damn good dude. I think that's how it would look if the factory had to do it, damn fine work. Keep it up!

[crownandmonster]

Originally posted by JOHNDOE83
Actually, I am/was gonna do it with the cr seat :D

And build a allum or emt conduit subframe, prob allum.


I highly doubt thin wall will be strong enough even for you just to drag race with.

I also don't see you saving any weight using alum pipe over the stock sub frame, but keep us posted on it I'm interested in the final product.

[05DodgeDakota]

Originally posted by crownandmonster
I highly doubt thin wall will be strong enough even for you just to drag race with.

I also don't see you saving any weight using alum pipe over the stock sub frame, but keep us posted on it I'm interested in the final product.

Its pretty common in quad dirt drags. Look at the quads in the first three guys' signatures in this thread:
http://www.trx450r.org/forum/121-dunes-desert-drag-racing/168562-new-texas-300-sand-drag-track.html

[crownandmonster]

Haha I guess I'll go eat my words now........

[Chukkinsod]

I was looking at doing the same thing only running a drag ported 370 set up. let me know how it works our for you.

[400exshop]

PM me your number john i have a new 426 build that is supper fast all motor no wheelie bar......8.25 in the 1/8 mile.

We do have spray on it but have not sprayd it yet.....also im building single a-arms set up from chrome moly.....and im going to strat building chrome moly sub frames.....

Just pm me....

[JOHNDOE83]

I made alot of progress, getting everything welded up the few days after xmas. All the fab work is done other then the motor mount on top.

I will get pics of the work today and have them later tonight, wait till you see how the pipe is, its fat and routed way different then a 250r.

[JOHNDOE83]

this is a pic of the expansion chamber on the ftz drag pipe compared to a fmf gnarly pipe.



http://i953.photobucket.com/albums/ae15/johndoe83_2010/blandish004.jpg



this is a partial pic of the head pipe/chamber together, outside of view theres a mid pipe and silencer.



http://i953.photobucket.com/albums/ae15/johndoe83_2010/blandish005.jpg



I cut the gnarly pipe right at the welds for the piece thats slides into the cr cylinder "flange", I then cut the ftz pipe directly at the welds for its 250r style "flange" then inserted the cr flange into the motor to see how it needed shaped to fit the ftz header and how it matched for fitting the pipe through the frame.

From the pic it looks like I did a good job matching it up, when its held flush together the header pipe floats between the frame and steering stem.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/blandish007.jpg



Heres another angle.



http://i953.photobucket.com/albums/ae15/johndoe83_2010/blandish009.jpg



And this is roughly what it will look like when done.



http://i953.photobucket.com/albums/ae15/johndoe83_2010/blandish008.jpg

[mineralgrey01gt]

looks so close to running not through the frame but doesnt look bad. Id try to knock that dent out of the FTZ pipe if possible. Id put money on it my old LRD adjustable pipe off my 250r would work on it

[JOHNDOE83]

you actually cant see that dent when its mounted, it looks like frame rub from previous owner.


I know it doesnt look like it fits, but when its held in place flat flush on the header flange it has 1/4 from the stem and 3/8 to 1/2 from frame rail. Thats if it welds on straight and in the same place.

The angle on the cr motor exhaust port is different from the angle a 250r motor has so it prob would fit the frame better but woulda needed just as much grind time to match the cr flange.

heres a video of the pipe installed on a 250r 400cc pilot motor.

this is the pipe I now own, you can see how much different its routed compared to mine.

http://www.youtube.com/watch?v=GCNEtP8pl5U

http://www.youtube.com/watch?v=NjX4_Vn2kGo


I also changed the kiker assembly, I now am gonna use a xr80 kick starter!

[JOHNDOE83]

Well I got alot of progress done today, but was only able to get a few pics.

At the end of the day I had the carb, electronics, radiator and all sorts of other stuff done...just didnt stop and take to many pics, sorry guys. Atleast now you know by the next time I post pics it will be essentially done.

I discovered the throttle cable for the cr was bad so I have to get a new one of those, Im using a 1985 cr80 radiator instead of the 250 rad, its smaller but thicker and the way the hoses are routed on the 80 rad make a better fit.

I also discovered that 400ex sprokets fit the cr sproket shaft and it made the sproket allignment perfect, so I stepped up the 13t to a 14t.

AND, If your chain slider is getting worn, you can grind it back smooth and get more usage out of it! So I did that to.

Heres the pics...

http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies013.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies014.jpg


CR 80 Radiator and where its going.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies010.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies011.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies012.jpg



Top motor mount....



http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies007.jpg


pipe welded and put into place, I got to find some smaller springs to make it fit perfectly into the head.



http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies006.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/newzies009.jpg.

[01boneless]

hows it going any updates?

[JOHNDOE83]

Its just about done, The only thing left to do is radiator hose's, fuel line and a mid pipe has to be made.

The kick start extension I kinda screwed up when I decided to switch it to a xr80 kick starter, now its slightly to short and rub's the brake assembly when you try to kick it, Its way to hard to bend it.... I just gotta make a new one.

That's all it need's before I can start test riding it, after it's test rode a few time's I can tear it apart again for the "Hybrid rebuild thread", it will consist of color changes and a few extra secret details.

I promise new pic's and more progress will be seen within the next week or two.

[J51S]

Sick build man can't wait to see the finished product:cool:

[JOHNDOE83]

Its almost ready to ride, I went to have a mid pipe made and the guy gave me a few ideas to try before paying him to make one, so im gonna go out and install the rest of he pipe today.

Then all I have left to do is fix the kick start, put new fluids int and take for its first ride!

Heres some pics of how it sits now.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/workandquad051.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/workandquad045.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/workandquad047.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/workandquad052.jpg

http://i953.photobucket.com/albums/ae15/johndoe83_2010/workandquad046.jpg

[J51S]

Holy zipties:eek2: lol but looks cool wonder how she rips

[mineralgrey01gt]

crazy how much smaller that radiator is than on the trx250r. Id try to get the trx radiator instead of that one personally. Seems like it would cool better especially if you put the front fenders back on

[J51S]

mineralgrey01gt crazy how much smaller that radiator is than on the trx250r. Id try to get the trx radiator instead of that one personally. Seems like it would cool better especially if you put the front fenders back on

Ya thats what I was thinking if he angles the pipe down more like a 250R he could get the other rad in there, but I'm not sure if the frame angles will allow it.

[honda400ex2003]

That pipe is qhite a bit bigger than mine thags for sure. Diameter wise at least lol. Looks good
man!

Steve

[tayyo789]

That radiator's fine for drag racing, which I know is what you're in to. Just have to watch it on the test ride and stuff. An inline temp guage is a must IMO

[JOHNDOE83]

Yeah Im deffinetly getting a inline temp reader, Im used to air cooled motors so I really need something that I can just look down and see.

For the test rides Im gonna keep the laser temp gun at my side.

I really wish I could use the bigger CR radiator, maybe after its running good and I go to re paint and grease everything Ill make the big radiator work or atleast stick a fan on it.

Whats A good temp for these 2 strokes to run at safely???

[steve181]

under 200

180 i would guess

[JOHNDOE83]

I got the kick starter Re-Made and I have coolant and new oil ready to go in, all I need now is mixed gas and the first test ride will begin.

gotta get batteries for the temp gun also :D

I think it may be possible to ride it on saturday!

[JOHNDOE83]

IT IS RIDEABLE!!!!

Went out today put new fluids in, mounted the kicker put a new airfilter on and 3 kicks later I was riding it down the road!

It leaks water like crazy out of the 90 degree elbow on the cylinder, the kicker is to weak and is already bending, other then that it rides like a beast!!!

It vibrates but its not Bad at all, Im gonna change the bars and hope it takes a lil bit out, but other then that its FASSST!!

With a 14t front sproket and a 39t rear and 18in slicks on a dirt road it rips harder then the EX did with knobbies, when the power band kicks in HOLD ON cause its going!

The big bore FTZ Pipe Im using was alot bigger then the gnarly pipe I took off, we were skeptical on how practical the pipe would be but letme tell you, The power band is way wider the it was before it has ALOT of low end power and the peak is INSANE, this quad has way more power and speed then it did in the CR chassis and its more controlable power.

I took it for three 5- 10 min rides and stopped to check the temp and it was never over 156 degrees at the cylinder!

The jetting seems to be fine so Im just gonna leave it for now, I need a better kicker shaft, I need to fix the leaks, I need to re grease and paint a few things and put on alot of new parts but this build was WAY worth it.

I rode with the silencer on the pipe for the first ride, then the screw had vibrated out so I took it off for the next 2 rides and I swear it picked up 3 HP!

Heres a VID of it running this was the second run I made, all I do in the vid is start it, ride it away, then come back, you can hear me opening it up down the road, It sounds GOOD!

http://s953.photobucket.com/albums/ae15/johndoe83_2010/?action=view&current=SUNP0154.mp4

[JOHNDOE83]

Here's some updated info on the hybrid project, Ive had some seat time and this thing has far exceeded my expectation's. It starts right up, idle's good and haul's butt. I made a custom hood to cover up the radiator and create a hood scoop to force air at the rad but it looks like a mailbox...lol.

I tried to make it look like a 250r or 250ex headlight but its kinda bigg, I also took my stickers off the plastic and mounted the silencer to make it more quiet. I took the drag bars off and put my low rise bars with a new foam honda pad on, I took off the rear shock setup and put my drag strut on.

It really ride's great!

Here's some pic's and some video of it running, let me know what you think about the hood "I know it's kinda big" but I want more opinions, let me know if you want a more detailed pic of something else also?

http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0160.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0159.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0161.jpg
http://i953.photobucket.com/albums/ae15/johndoe83_2010/SUNP0162.jpg


Here's the video!

walk around
http://i953.photobucket.com/albums/ae15/johndoe83_2010/th_SUNP0157.jpg (http://s953.photobucket.com/albums/ae15/johndoe83_2010/?action=view&current=SUNP0157.mp4)


riding and at the end heat temp reading.
http://i953.photobucket.com/albums/ae15/johndoe83_2010/th_SUNP0158.jpg (http://s953.photobucket.com/albums/ae15/johndoe83_2010/?action=view&current=SUNP0158.mp4)

[JOHNDOE83]

Newerish handle bars and some test riding.

does donuts with the extended swingarm on pavement effortlessly with not alot of throttle.

http://i953.photobucket.com/albums/ae15/johndoe83_2010/th_SUNP0163.jpg (http://s953.photobucket.com/albums/ae15/johndoe83_2010/?action=view&current=SUNP0163.mp4)

[Ruby Soho]

sweet project man. i see your in west palm beach fl correct? where do yo ride around here? i just moved to jupiter.

[JOHNDOE83]

Actually tomorrow were gonna go riding at L-Cross, theres also underhills and dirty foot adventures.

underhills is closer to jupiter, l-cross is at the north end of lake okeechobee and DFA is in lakeland, those are the closest places to ride "legally" unfortunatly.

Under hills is off of 714 and bee line hwy "710", its kinda small and not really maintained like like L-cross or DFA, but for some decent riding its ok, the old man frowns upon sport quads and only lets certain people ride them sometimes.

heres some links if you dont already have them.

www.atvflorida.com

www.plantbamboo.com "underhills"

www.l-cross.com

www.dirtyfootadventures.com

theres also the new devils mud garden but I havent been there, yet its supposed to be outside of clewiston.... I think.

[Ruby Soho]

i knew there were some places to ride around here, just had to talk to someone haha. thanks for the info, im going to try and get out to those places. maybe ill run into you sometime

[JOHNDOE83]

just wanted to update this thread.

This is the new drag cut frame and almost exactly how I intended the drag quad build to end.

My next project is a cr80r/400ex hybrid mini mx build.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00233_zps5fda3d5d.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00233_zps5fda3d5d.jpg.html)http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00258_zps58217519.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00258_zps58217519.jpg.html)



I re made the motor mounts.


http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00213_zpsbe2cef79.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00213_zpsbe2cef79.jpg.html)http://i953.photobucket.com/albums/ae15/johndoe83_2010/CAM00214_zps43bcdbe4.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/CAM00214_zps43bcdbe4.jpg.html)

Re mounted radiator


http://i953.photobucket.com/albums/ae15/johndoe83_2010/IMG_20130126_180341.jpg (http://s953.photobucket.com/user/johndoe83_2010/media/IMG_20130126_180341.jpg.html)